WO2013133231A1 - Manufacturing method and manufacturing device for optical-use laminate structure - Google Patents

Abstract

The objective of the present invention is to provide a method and device for manufacturing an optical-use laminate structure which, despite originating with an OCR application method, resolves problems of the OCR application method, and in addition, has merits exceeding OCA affixation. In a first step (P1), a radical polymerization type active energy ray curable optically transparent resin solution (R) is applied upon a substrate (1) in order to form a monolamellar fluid uncured layer (L1) upon the substrate (1). In a second step (P2), by irradiating the active energy rays onto the uncured layer (L1) in order to cause curing to proceed, the uncured layer (L1) is changed to a thickened layer (L2) in which fluidity is reduced. In a thid step (P3), the thickened state of the thickened layer (L2) is maintained.

Description

Method and apparatus for manufacturing optical laminated structure

Although the present invention begins with the OCR coating method (method of coating a liquid optical transparent resin on a substrate), the conventional OCA bonding method (substrate) as well as the conventional OCR coating method is used. In particular, the present invention relates to a method for manufacturing an optical laminated structure and a manufacturing apparatus having an advantage over a method for adhering a sheet-like optical transparent adhesive.

[Optical transparent resin (OCR) and optical transparent adhesive (OCA)]
(Meaning of terms)
-1-
In the technical field related to the optical laminated structure mounted on various electronic devices such as input devices and display devices, the terms OCR and OCA are often used.

-2-
OCR is an abbreviation for Optical Clear Resin and is handled in a resin liquid state.

-3-
OCA is an abbreviation for Optical Clear Adhesive, and is handled in the form of an adhesive in the form of a sticky sheet (in the case of narrow width, tape). Since OCA has adhesiveness, it is in the form of a “separator / OCA / separator” laminate in which both sides of OCA are coated with separators (sheets having peelability), or a sheet having double-sided peelability is used as a separator. It is obtained or prepared in the form of a wound product of “double-sided peelable separator / OCA”.

(Typical usage of OCR and OCA)
-1-
In the optical laminated structure using the former OCR, between one substrate and the other substrate (for example, “between cover glass and sensor glass” or “between cover glass and liquid crystal module”). In many cases, an OCR intervening curable resin liquid is used.
The intervention of the curable resin liquid between the two substrates is usually achieved by applying the resin liquid on one substrate with a dispenser and then covering the other substrate from the applied layer. In some cases, it is also possible to inject a resin liquid into the gap in a state where two substrates are close to each other.
Curing of the curable resin liquid interposed between the substrates is performed by heating when the resin liquid is a thermosetting type, and by ultraviolet irradiation when the resin liquid is an ultraviolet curable type.

-2-
On the other hand, in the case of an optical laminated structure using the latter OCA, taking as an example the case where it is obtained or prepared in the form of a laminated product in which both sides of OCA are coated with a separator as described above, The OCA with one side exposed while being peeled and removed on one side is attached to one side of one substrate, and then the remaining separator covered with the attached OCA is peeled and removed while the surface with the peel removed is exposed. To use the other board.

(Problems of OCR application method and OCA application method)
(Part 1) Problems of OCR coating method When OCR, which is a resin liquid, is interposed between both substrates by the above-mentioned method, various troubles occur as shown in the schematic diagram of FIG. It is difficult to prevent. The diagram on the left side of FIG. 4 is a diagram immediately after the application of OCR, which is a resin liquid, on the substrate (1). However, as shown in the upper right diagram of FIG. 4, the peripheral edge portion of the applied coating layer tends to sag over time. Further, as shown in the lower right diagram of FIG. 4, when the OCR-coated substrate (1) is moved or flipped up and down for stacking with the other substrate (2) (not shown), gravity is applied. In addition, the thickness of the coating layer tends to be biased by centrifugal force. In addition, troubles such as the OCR sandwiched between the substrate (1) and the substrate (2) may protrude from the peripheral edge of the structure.

(Part 2) Problems of the OCA sticking method-
On the other hand, the latter OCA pasted on one substrate is the other substrate (a black and white printing stepped portion called “decorative portion” is provided around the other substrate and bordered. In many cases, the sag and unevenness of the resin liquid does not occur as in the case of the OCR coating method described above, but the printed step portion around the other substrate and the OCA sticking. It is easy to produce a gap between the parts. (Additionally, the white decorative part is easier to pass light than the black decorative part, so either add a white layer to increase the thickness, or provide a black undercoat layer on top of it. (For this reason, the white decorative part is inevitably thicker than the black decorative part.)
Since OCA is a sheet-like adhesive that is compressively deformed but does not inherently have fluidity, as described in detail below, it should be adhered tightly so as not to create a gap in a predetermined area of the substrate. This is because it is difficult in principle. This will be described with reference to FIG.

-2-
FIG. 5 (A) is an explanatory diagram showing the positional relationship when a substrate (2) having a printed border (2E) formed on the periphery is bonded to a substrate (1) having a sheet-like OCA attached thereto. It is.

-3-
At first glance, as shown in FIG. 5B, the OCA on the substrate (1) may be positioned exactly inside the step (2E) of the edge (2E) of the substrate (2) by bonding. It turns out that it is not easy. This is because there are four sides of the border (2E) and four corners of the border (2E), and it is extremely difficult to make OCA interpose all over them.
Then, if a gap remains on the inner side or corner portion of the edging (2E), as shown in the plan view (perspective view) when viewed from the substrate (2) side in FIG. The band-like bubbles (b) can be visually observed along the level difference with 2E), and the laminated structure of “substrate (2) / OCA / substrate (1)” in such a state has a commercial value. It will be lost.

-4-
Therefore, as shown in FIG. 5 (D), it is more preferable that the portion around the OCA on the substrate (1) reaches the middle portion of the edge (2E) of the substrate (2) by bonding. It can be said that it is certain to prevent the occurrence. At this time, in the OCA, the peripheral part reaching the part in the middle of the edging (2E) is crushed, so that the OCA of the crushed part becomes a thin film compared to other parts. As long as the thin film portion is between the inner side and the outer side of the edging (2E), there will be no OCA short (underfilling) or overhanging (overfilling) troubles. The error can be absorbed. Therefore, if the OCA sticking operation is performed with high accuracy, defective products should not be produced.
However, even in this case, it is not easy for the OCA to fill a gap at the position indicated by the tip of the arrow in FIG. This is because OCA originally has no fluidity. Therefore, when the portion is viewed from the outside, the strip-shaped bubble (b) may be visually observed along the inner side of the step as shown in FIG.

(Measures and limitations in OCR application method and OCA adhesion method)
-1-
First, when relying on the former OCR coating method, conventionally, by slightly sacrificing smooth coating properties and leveling properties (both are properties related to fluidity), by making the viscosity of the coating solution as high as possible. It was made difficult to cause sag and bias.
However, when this OCR coating method is used, it has been difficult to eliminate sagging and unevenness while ensuring fluidity and leveling. This is because having “fluidity and leveling properties” and “having anti-sag and anti-bias” properties are contradictory to each other.

-2-
On the other hand, when the latter OCA sticking method is used, since there is a principle restriction that OCA does not have fluidity, it is conventionally necessary to stick OCA as accurately as possible to a predetermined area of a substrate. Careful attention was paid to the control of pressure and temperature in the sticking process, and the OCA was softened to prevent the formation of the band-like bubbles (b).
As a result, in the case where the thickness of the OCA on the substrate (1) is about 200 μm, for example, and the thickness (that is, the step) of the border (2E) provided by printing on the substrate (2) is about 6 to 10 μm, for example. I managed to deal with it by paying attention to the above.
However, in the case where the thickness (that is, the level difference) of the rim (2E) is, for example, 50 to 60 μm as in the white “decorating portion” described above, the above-mentioned attention is no longer taken. Was reaching the limit of being unable to deal with.

[Patent Literature]
Next, patent literature considered to be related to the present invention will be examined.
The following Patent Document 1 is a document that describes the vacuum bonding between substrates and the use of an ultraviolet curable adhesive.
Patent Document 2 below is a document relating to a display device having a structure in which a substrate and a display panel are laminated and bonded via an ultraviolet curable resin layer, and also describes provisional curing and main curing of the ultraviolet curable resin. .
Therefore, these patent documents 1 and 2 seem to be the prior art which should be contrasted with this invention.

(Patent Document 1)
-1-
Claim 1 of Japanese Patent Application Laid-Open No. 2001-250289 (Patent Document 1) discloses the following method of vacuum bonding of substrates.
-A method of bonding two substrates together with an adhesive,
A step of annularly applying a cationic ultraviolet curable adhesive to at least one of the two substrates,
A step of spreading the annularly applied adhesive over substantially the entire substrate;
An ultraviolet irradiation step of irradiating the adhesive with ultraviolet rays to initiate a curing reaction of the adhesive;
A step of bonding the two substrates in a vacuum atmosphere via an adhesive whose curing reaction has been started, and a method for vacuum bonding the substrates.
(Note that claim 4 shows a substrate vacuum bonding apparatus comprising an adhesive application device, an adhesive diffusion device, an ultraviolet irradiation device, and a vacuum atmosphere forming device.)

-2-
In claims 2 and 8 of Patent Document 1, the above adhesive is “a transparent, cationic UV-curable adhesive that does not significantly impede the transmission of DVD laser light mainly having a wavelength of 635 nm or 650 nm. It is stipulated.

-3-
The following paragraph of this patent document 1 has the following description.
Paragraph 0017 states that “It is a transparent cationic cationic UV-curing adhesive having a low viscosity (3500 cps or less) and a fast curing speed” (paragraph 0017).
In paragraph 0020, “Use a cationic UV-curable adhesive that is transparent, has a low viscosity (3500 cps or less), and has a fast curing speed (for example, within 5 minutes)”.
In this paragraph 0020 and FIG. 1, it is shown that a dispenser is used as an example of an adhesive application device.
Paragraph 0030 states that “the curing time as an example of the present embodiment is about 5 minutes, so that the bonding is performed within 1 to 2 minutes after irradiation with ultraviolet rays”.
Paragraph 0037 states that “curing may be completed outside the vacuum atmosphere because the cationic adhesive has the property of being completely cured in a certain period of time after being irradiated with ultraviolet rays”.
In paragraph 0039, "If this adhesive is made into a transparent or cationic translucent cationic UV-curable adhesive that does not significantly impede the transmission of DVD laser light mainly having a wavelength of 635 nm or 650 nm, It can be applied not only to bonding substrates that do not allow UV light to pass through, but also to bonding substrates that pass UV light, and can be used widely for bonding optical disks that currently exist. "

(Patent Document 2)
-1-
Claim 1 of Japanese Patent Application Laid-Open No. 2011-145534 (Patent Document 2) shows the following manufacturing method.
A method of manufacturing a display device with a front window in which a substrate and a display panel are bonded with an ultraviolet curable resin,
-Forming an ultraviolet curable resin between the display panel and the substrate;
-After irradiating ultraviolet rays from the side of the substrate and partially curing the ultraviolet curable resin (that is, temporarily curing only the portion corresponding to the transmission pattern of the ultraviolet irradiation mask) and leaving it for a predetermined time,
Bonding the substrate and the display panel by main curing the ultraviolet curable resin by irradiating ultraviolet rays from the substrate side;
The manufacturing method of the display apparatus with a front window characterized by these.
(The claim 10 shows a display device with a front window, and the claim 14 shows a bonding device for the display device with a front window.)

-2-
Here, "partially cured" in the constituent requirements of "partially irradiating ultraviolet rays from the substrate side and partially precuring the ultraviolet curable resin," as described above, “Irradiation is performed only on a partial region of the ultraviolet curable resin through the ultraviolet irradiation mask, and the ultraviolet curable resin in the masked portion is not cured and maintains fluidity” (paragraph 0012). That is).

-3-
In the example of this patent document 2, application is performed by discharging the ultraviolet curable resin in a linear manner from the dispenser to the back side of the front window and changing the position to reciprocate (paragraph 0021). The display area is, for example, 3 inches diagonal (the length of the diagonal is 3 inches) (paragraph 0022). The initial viscosity of the ultraviolet curable resin is, for example, 2300 mPa · sec (paragraph 0024).

-4-
In FIG. 7, the “liquid crystal panel” and the “inverted front window after application of optical resin” are pasted together, then temporarily fixed by performing the first ultraviolet irradiation, and left to stand. Curing is achieved by performing secondary ultraviolet irradiation. During the standing after the temporary curing, the ultraviolet curable resin that has not been temporarily cured flows to an optimum thickness, and the bubbles diffuse to the outside (paragraph 0035).

-5
An example of the ultraviolet transmission pattern formed on the ultraviolet irradiation mask is nine circles (paragraph 0032, FIG. 11), and therefore the ultraviolet curable resin is temporarily cured into a columnar shape corresponding to the nine circle portions ( Paragraph 0032).
Other examples of the ultraviolet transmission pattern are a cross and a line (paragraph 0033, FIG. 12), and a combination of a line and a circle (paragraph 0033, FIG. 13).

JP 2001-250289 A JP 2011-145534 A

(Regarding Patent Document 1)
-1-
The invention of Patent Document 1 is understood to have the most characteristic technical idea in the idea of “applying a cationic ultraviolet curable adhesive to at least one of the substrates when the substrates are bonded together”. This is because the cationic ultraviolet curable adhesive has such a property that once the ultraviolet ray is irradiated to start the curing reaction, the curing reaction continues even after the ultraviolet ray irradiation is stopped to reach the main curing.
Then, the object of the invention of Patent Document 1 is to attach recording substrates having reflective films such as aluminum and gold, as in paragraphs 0006 to 0008 and paragraph 0039, that is, a recording substrate that does not allow ultraviolet rays to pass through. The two are bonded together (typically applied to optical disk bonding).
(In the invention of Patent Document 1, as for the method of applying the ultraviolet curable adhesive, there is only mention of a method of applying it in an annular manner with a dispenser, as in paragraph 0020 and FIG.

-2-
However, the object (targeted), technical idea, specific means and operational effects of the invention of Patent Document 1 are basically different from those of the present invention.

(Regarding Patent Document 2)
-1-
In the invention of Patent Document 2, an ultraviolet curable resin is formed between a display panel and a substrate, and then a portion of the ultraviolet curable resin is temporarily cured by partially irradiating ultraviolet rays through a mask from the substrate side. (Only the transparent part of the mask is temporarily cured), and after leaving for a predetermined time, the entire ultraviolet curable resin is fully cured by irradiating ultraviolet rays from the substrate side, thereby bonding the substrate and the display panel. It is characterized by doing.

-2-
Thus, in the invention of Patent Document 2, the temporary curing and the main curing from the substrate side by the irradiation of ultraviolet rays are both performed in the laminated state of “substrate / ultraviolet curable resin layer / display panel”. This is basically different from the present invention. In addition, the temporary curing in the invention of Patent Document 2 does not mean “semi-curing” of the entire ultraviolet curable resin layer, but only the pattern portion (for example, if the transmission pattern of the mask is a circle, Since the temporary curing of the resin layer is performed in the thickness direction of the resin layer, the temporary cured portion is a cylinder). This point is also fundamentally different from the present invention.
The invention of Patent Document 2 is fundamentally different from the present invention in technical idea and specific means.

(Object of invention)
Although the present invention is based on the OCR coating method (method of applying a liquid optical transparent resin to the substrate), the problems of the OCR coating method are solved, and the OCA bonding method is used. Method for producing an optical laminated structure having advantages over (a method for attaching a sheet-like or tape-like optical transparent adhesive to a substrate) (and an apparatus for producing such an optical laminated structure) ).
In other words, the OCR coating method and the OSA adhering method, both of which are conventional techniques, are technical techniques that involve the side of the master but have the side of the poor, and the present invention relates to these conventional techniques. The purpose is to provide a technology that eliminates the disadvantages of all at once.

The manufacturing method of the optical laminated structure of the present invention is as follows.
By applying a radical polymerization type active energy ray-curable optically transparent resin liquid (R) on the substrate (1), the resin liquid (R) has a single-layered fluid uncured state on the substrate (1). A first step (P1) for obtaining a laminate having a layer configuration of “uncured layer (L1) / substrate (1)” in which the layer (L1) is formed;
By irradiating an active energy ray to the uncured layer (L1) of the laminate obtained in the first step (P1) to advance the curing, the uncured layer (L1) has reduced fluidity. A second step (P2) for obtaining a laminate having a layer configuration of “thickening layer (L2) / substrate (1)” changed to a thickening layer (L2); and
Third step (P3) for maintaining the thickened layer (L2) of the layered structure of “thickened layer (L2) / substrate (1)” after the second step (P2) in its thickened state.
It is characterized by comprising.

The optical laminated structure manufacturing apparatus of the present invention includes:
By applying a radical polymerization type active energy ray-curable optically transparent resin liquid (R) on the substrate (1), the resin liquid (R) has a single-layered fluid uncured state on the substrate (1). Application means (M1) for obtaining a laminate having a layer structure of “uncured layer (L1) / substrate (1)” in which the layer (L1) is formed,
By irradiating active energy rays to the uncured layer (L1) of the laminate having the layer structure of “uncured layer (L1) / substrate (1)”, the uncured layer (L1) is cured. ) Is a thickened active energy ray irradiating means (M2) for forming a layered product of “thickened layer (L2) / substrate (1)” in which the thickened layer (L2) is reduced in fluidity. )When,
Linking and controlling each step of forming the uncured layer (L1) on the substrate (1), forming the thickened layer (L2), and maintaining the thickened state of the thickened layer (L2) Linkage control means (C1)
It comprises.

(Function 1 of the present invention)
-1-
Generally, the ultraviolet curable resin composition includes a radical polymerization type represented by an acrylate type and a cationic polymerization type represented by an epoxy type. There is also a radical polymerization type mainly composed of silicone.
Comparing radical polymerization type ultraviolet curable resin composition (referred to as “the former”) and cationic polymerization type ultraviolet curable resin composition (referred to as “the latter”), according to the literature, the following tendencies are observed. It is said that there is.
(A) Regarding the cure shrinkage, the latter has a smaller shrinkage than the former.
(Ii) Regarding the oxygen curing inhibition, the former is hard to be inhibited by oxygen, whereas the latter is hard to be inhibited by oxygen.
(C) When the ultraviolet irradiation is stopped, the curing reaction is stopped in the former, whereas the curing reaction is continued in the latter.

-2-
The invention of claim 1 of Patent Document 1 described in the section of [Background Art] previously requires the use of a cationic ultraviolet curable adhesive. Therefore, when the curing reaction is started by ultraviolet irradiation, the curing reaction proceeds even if the ultraviolet irradiation is stopped, and it is difficult to be inhibited by oxygen, so that the main curing takes about 5 minutes after the irradiation is stopped. Understood.

-3-
On the other hand, in the present invention, it is an essential requirement to use a radical polymerization type optically transparent resin liquid (R). Therefore, the uncured layer (L1) formed in the first step (P1) is irradiated with an active energy ray to cure, thereby increasing the viscosity of the uncured layer (L1) with reduced fluidity. After carrying out the second step (P2) to obtain a layered product of “thickening layer (L2) / substrate (1)” changed to (L2), the layered product is left as it is in the third step (P3). Even if it is allowed to stand, the thickened layer (L2) after the second step (P2) can be maintained in its thickened state.
And even if it is made to wait until it starts to the 5th process (P5) through the 4th process (P4) mentioned later after the 3rd process (P3), the thickening layer (L2) still remains in the thickened state. Can be maintained.
In addition, the thickening layer (L2) after the second step (P2) is in contact with air (that is, oxygen) during the period of being left standing or waiting. Contributes to maintaining the thickened state.
Thus, the technical idea of the present invention is fundamentally different from the invention of Patent Document 1.

(Action mechanism 2 of the present invention)
As already described, in the invention of Patent Document 2, both the temporary curing from the substrate side by ultraviolet irradiation and the main curing are performed in a laminated state of “substrate / ultraviolet curable resin layer / display panel”. Therefore, it is fundamentally different from the present invention.
In addition, the temporary curing in the invention of Patent Document 2 is not the entire “temporary curing” of the formed ultraviolet curable resin layer, but only the pattern portion (for example, if the pattern is a circle, the temporary cured portion is a cylinder). However, this point is also fundamentally different from the present invention.
Thus, the present invention is basically different from the invention of Patent Document 2 in both technical idea and specific means.

(Effect of the present invention)
-1-
In the first step (P1), which is the beginning of the method for producing an optical laminated structure of the present invention, the substrate (1) is coated with a radical polymerization type optical transparent resin liquid (R). ) Is a step of obtaining a layered product of “uncured layer (L1) / substrate (1)” in which a single-layered fluid uncured layer (L1) of the resin liquid (R) is formed thereon. .
This first step (P1) is in common with a conventional OCR coating method (a method of coating a substrate with a liquid optical transparent resin).
By the way, when relying on the conventional OCR coating method, it has been extremely difficult to eliminate sagging and unevenness while securing fluidity and leveling properties. However, in the present invention, in the second step (P2), The uncured layer (L1) formed in the step (P1) is irradiated with an active energy ray to advance the curing, whereby the uncured layer (L1) has a reduced viscosity and the thickened layer (L2). Since the laminated body having the layer configuration of “thickening layer (L2) / substrate (1)” that has been changed to “3” is obtained, drooping and unevenness can be eliminated while ensuring the necessary fluidity and leveling properties. . That is, the advantages of the conventional OCR coating method are utilized and the disadvantages of the conventional OCR coating method are eliminated.

-2-
The conventional OCA sticking method using a sheet-like adhesive does not have the trouble of sagging and unevenness like the OCR coating method, so the sticking operation to the board is easy. ) Are likely to occur along the inner side, and depending on the level of the step, it is difficult to fill the gap.
However, since the thickening layer (L2) by the second step (P2) in the present invention has appropriate fluidity, the gap can be filled cleanly.
Moreover, also when bonding another board | substrate (2) from the said thickening layer (L2) according to a 4th process (P4) in the post process, this thickening layer (L2) is the pressure at the time of the bonding. Since it flows so as to follow, there is no blind spot due to insufficient filling of the thickened layer (L2) in the laminated body after lamination, so even if the main curing is performed according to the fifth step (P5) No bubbles remain between the hardened layer (L3) and the other substrate (2).
Thus, in this invention, since the unhardened layer (L1) formed by the 1st process (P1) has become the thickening layer (L2) by irradiation of the active energy ray in the 2nd process (P2). In addition to playing the role of the conventional OCA sticking method, the OCA sticking method completely eliminates the drawbacks that are difficult to overcome.

-3-
As described above, the present invention is not a technique positioned between the conventional OCR coating method and the conventional OCA adhesion method, and both of these methods are new qualitatively different in terms of technical idea and effect. It can be said that it is the creation of a technical idea.

Hereinafter, the present invention will be described in detail.
FIG. 1 is a schematic explanatory view of a manufacturing method and a manufacturing apparatus of the present invention.

[Method for producing optical laminated structure]
The method for producing an optical laminated structure of the present invention comprises a first step (P1), a second step (P2), and a third step (P3), as will be described in detail below.
After the third step (P3), a fourth step (P4) and a fifth step (P5) described later can be provided. Further, the fourth step (P4) and the fifth step (P5) can be carried out as an integrated step (that is, in-line) following the first to third steps (P1 to P3 steps).

(First step (P1))
-1-
In the first step (P1), a radical polymerization type optically transparent resin liquid (R) is applied onto the substrate (1), so that the single layer fluidity of the resin liquid (R) is applied onto the substrate (1). This is a step of obtaining a laminate having a layer configuration of “uncured layer (L1) / substrate (1)” in which a certain uncured layer (L1) is formed.
The optical transparent resin liquid (R) is applied onto the substrate (1) by using the application means (M1) (in particular, by using a coater with a slit nozzle that discharges from a wide slit). This will be described in detail in the description of the apparatus of the present invention.

-2-
As the substrate (1), various types of substrates such as glass substrates, plastics substrates, ceramic substrates, semiconductor substrates, woven fabric substrates, substrates with conductive layers, liquid crystal modules, liquid crystal display panels, etc. Various multi-layer or composite substrates such as display modules and recording substrates with a reflective layer are used. From a functional viewpoint, cover glass, sensor glass, various modules, and the like are exemplified.

-3-
The optically transparent resin liquid (R) is the “optically transparent resin (OCR)” described in the background section. In the present invention, the second step (P2) (and the fifth step (P5)). Therefore, the optically transparent resin liquid (R) is used to increase the viscosity or cure when irradiated with active energy rays (that is, ultraviolet rays or electron beams).
As the optical transparent resin liquid (R), either an ultraviolet curable resin composition or an electron beam curable resin composition can be used. However, when an electron beam curable resin composition is used, the burden of equipment costs is large. Therefore, when the productivity corresponding to it is required, an electron beam curable resin composition is often used. When an electron beam curable resin composition is used, it is not necessary to use a photoinitiator or a sensitizer in the composition.
Therefore, it is recommended to use an ultraviolet curable resin composition for production on a normal scale.
In describing the present invention, the case where an ultraviolet curable resin composition is used will be described below, but this does not exclude the use of an electron beam curable resin composition.

-4-
When an ultraviolet curable resin composition is used as the optical transparent resin liquid (R), a composition composed of a photopolymerizable prepolymer (photopolymerizable oligomer), a photopolymerizable monomer, a photoinitiator, an auxiliary agent, and the like is used. Used. At present, various ultraviolet curable resin compositions are marketed by many manufacturers.
Here, examples of the photopolymerizable prepolymer include polyester acrylate, polyurethane acrylate, epoxy acrylate, polyester urethane acrylate, and polyol acrylate. Acrylate is a concept that includes methacrylate.
Examples of photopolymerizable monomers are monofunctional, bifunctional, trifunctional or higher polyfunctional acrylates.
Photoinitiators are often used in combination with sensitizers.
Examples of auxiliary agents include light stabilizers, heat stabilizers, and plasticizers. Solvents are not used in principle, but can be used in small amounts.

-5
As described above, in the first step (P1) of the present invention, the resin is applied onto the substrate (1) by applying a radical polymerization type optical transparent resin liquid (R) onto the substrate (1). This is a step of obtaining a laminate having a layer configuration of “uncured layer (L1) / substrate (1)” in which a single-layered fluid uncured layer (L1) of liquid (R) is formed.
In the first step (P1), an uncured layer (L1) of the resin liquid (R) is formed on the substrate (1), and the resin liquid (R) is “between two substrates”. The uncured layer (L1) is not formed.

-6-
Regarding the degree of viscosity of the radical polymerization type optically transparent resin liquid (R) to be applied (approximately the same as the degree of viscosity of the uncured layer (L1) as the application layer), the viscosity according to ASTM D1084 is, for example, 10 to Since the thing of about 50000 mPa / 25 degreeC can be procured from a market, the thing of a suitable viscosity is selected from them. In general, those having a viscosity of 500 to 30000 mPa / 25 ° C., more preferably 800 to 20000 mPa / 25 ° C., particularly 1000 to 15000 mPa / 25 ° C. are often used. Among such viscosities, those with intermediate viscosities recall the degree of honey viscosity and thixotropic properties (thixotropic properties) at room temperature of 25 ° C.
In addition, since the curing rate (or degree of curing) of the optically transparent resin liquid (R) to be applied and the uncured layer (L1) that is the coating layer is a resin liquid at a stage before irradiation with active energy rays, It is almost 0 or close to 0.

-7-
The thickness of the single layer application of the optical transparent resin liquid (R) on the substrate (1), that is, the thickness of the uncured layer (L1) is not particularly limited, but is applied to electronic devices such as input devices and display devices. In the case, it is often 0.01 to 2 mm, more preferably 0.05 to 1.0 mm, and particularly 0.08 to 0.5 mm.

(Second step (P2))
-1-
In the second step (P2), the uncured layer (L1) is formed by irradiating the active energy ray to the uncured layer (L1) formed in the first step (P1) to advance the curing. Is a step of obtaining a laminated body having a layer structure of “thickened layer (L2) / substrate (1)” that is changed to a thickened layer (L2) with reduced fluidity. A typical example of the active energy ray to be irradiated is ultraviolet rays, and an electron beam can be used in some cases.

-2-
In the present invention, a model “Varian 610-IR” manufactured by VARIAN was used, and the thickened material was set in a sample holder for analysis. In a preliminary experiment, an appropriate peak that can be quantitatively measured is selected from those whose peaks decrease with the progress of the curing reaction due to ultraviolet irradiation, and the peak of interest is selected. Based on the peak height or area at the time of curing, the curing rate (or the degree of curing) was determined from the degree of decrease in the peak height or area accompanying the curing reaction. Since the degree of reduction of the uncured product is 0, the curing rate (or the degree of curing) is 0%, and the curing rate (or the degree of curing) when the curing progresses to become a completely cured product is 100%.
In the present invention, it is desirable to set the curing rate (or degree of curing) of the thickening layer (L2) within the range of 20 to 80%. A more preferred range is 25 to 70%, and a particularly preferred range is 30 to 60%.

(Third step (P3))
-1-
In the third step (P3) of the present invention, the thickening layer (L2) of the layered structure of “thickening layer (L2) / substrate (1)” after the second step (P2) is increased. It is a process of maintaining a viscous state. The maintenance of the thickened state is based on the property of the “thickened layer (L2)” formed in the second step (P2).
Thus, the third step (P3) plays a role of maintaining the curing rate (or the curing degree) related to the degree of viscosity of the thickened layer (L2) after the second step (P2). The maintenance time can be, for example, a relatively short time of about 10 seconds to a long time of several hours, several days or more, but the following steps (fourth step (P4) and fifth step (described later)) Since the third process (P3) can be performed using the storage and standby time during P5)), the process is not disadvantageous.
This third step (P3) appears to be a passive step, but ensures the properties and quality of the final product (input device or display device) by maintaining the degree of viscosity of the thickening layer (L2). It can be said that this is a necessary process.

-2-
When the irradiation of active energy rays is stopped in the second step (P2), since the original optical transparent resin liquid (R) is a radical polymerization type resin liquid, the viscosity of the thickening layer (L2) is determined there. It stops and the value is effectively maintained thereafter. The fact that the thickening layer (L2) formed on the substrate (1) is exposed to an air atmosphere (that is, an oxygen atmosphere) also means that the degree of viscosity of the thickening layer (L2) is maintained as it is or practically. Contributing to that.

(4th process (P4) and 5th process (P5))
-1-
After the third step (P3), the next fourth step (P4) and fifth step (P5) can be carried out (in-line or at another facility in the factory).
However, the laminated structure after the third step (P3) (a laminated body having a layer structure of “thickening layer (L2) / substrate (1))” can itself be supplied to the market as a product. Therefore, the next fourth step (P4) and fifth step (P5) may be performed in a factory of a supplier company (for example, a company having a bonding apparatus).

-2-
In the fourth step (P4), after the third step (P3), the layered structure of “thickening layer (L2) / substrate (1)” is subjected to a vacuum condition with another substrate (2). To form a laminate having a layer configuration of “substrate (2) / thickening layer (L2) / substrate (1)” or “substrate (1) / thickening layer (L2) / substrate (2)”. It is.
A 5th process (P5) is a process of irradiating an active energy ray with respect to the laminated body after a 4th process (P4), and making the said thickening layer (L2) into a hardened layer (L3).

-3-
First, as the substrate (1), “a variety of single-layer or multi-layer (composite) substrates including a glass substrate, a plastic substrate, a ceramic substrate, a semiconductor substrate, a woven fabric substrate, and various modules” is used. As described above, the other substrate (2) used in the fourth step (P4) is a substrate to be a counterpart when mating with the substrate (1). The same thing is used.

-4-
By the irradiation of the active energy ray in the fifth step (P5), main curing, which is a new curing reaction, is started for the thickened layer (L2) in which the curing reaction has completely or practically stopped. The thickening layer (L2) described above is intermediate between “substrate (2) / thickening layer (L2) / substrate (1)” or “substrate (1) / thickening layer (L2) / substrate (2)”. Since both sides of the layer are covered with the substrate, air (that is, oxygen having an action of inhibiting the curing reaction) is blocked. Therefore, the curing reaction of the thickened layer (L2) proceeds smoothly by the second irradiation of active energy rays, and the thickened layer (L2) becomes the main cured layer (L3).
The irradiation with the active energy ray in the fifth step (P5) may be performed from either the substrate (1) or the substrate (2) as long as the active energy ray is transparent.

[Optical laminated structure manufacturing apparatus / part 1]
(Manufacturing apparatus for performing the first step (P1) to the third step (P3))
-1-
An apparatus for manufacturing an optical laminated structure of the present invention for carrying out the first step (P1) to the third step (P3) of the manufacturing method described above,
By applying a radical polymerization type active energy ray-curable optically transparent resin liquid (R) on the substrate (1), the resin liquid (R) has a single-layered fluid uncured state on the substrate (1). Application means (M1) for obtaining a laminate having a layer structure of “uncured layer (L1) / substrate (1)” in which the layer (L1) is formed,
By irradiating active energy rays to the uncured layer (L1) of the laminate having the layer structure of “uncured layer (L1) / substrate (1)”, the uncured layer (L1) is cured. ) Is a thickened active energy ray irradiating means (M2) for forming a layered product of “thickened layer (L2) / substrate (1)” in which the thickened layer (L2) is reduced in fluidity. )When,
Linking and controlling each step of forming the uncured layer (L1) on the substrate (1), forming the thickened layer (L2), and maintaining the thickened state of the thickened layer (L2) Linkage control means (C1)
It comprises.

(Applying means (M1))
-1-
The coating means (M1) for forming the uncured layer (L1) is not particularly limited as long as it is a means that can apply the radical polymerization type optical transparent resin liquid (R) in layers on the substrate (1).

-2-
The first thing that comes to mind as the application means (M1) is an application means using a dispenser as used in Patent Document 1 and Patent Document 2 mentioned in the section of “Background Art”. The next thing that comes to mind is the means for applying by screen printing and the means for applying by inkjet.

-3-
However, among these applying means, the means for applying using the dispenser is to reciprocate the dispenser in order to apply the optical transparent resin liquid (R) so as to cover the entire predetermined area of the substrate (1). Since the resin liquid (R) after application must flow so that the remaining gap portion of the application is filled after being applied in the form of streaks or dots, the dispenser scanning time and the resin liquid (R) There is an aspect that the time required for the flow becomes long and the improvement of the processing speed is limited.

-4-
The means for applying by screen printing is means for printing the optically transparent resin liquid (R) on the substrate (1) through the eyes of the screen, but the viscosity of the resin liquid (R) must be set high; In order to form a thick print layer, it is necessary to make the screen coarser, and in that case, the peripheral edge of the print layer is difficult to sharpen; the screen gradually becomes clogged as operations are repeated. Since it is unavoidable, the film thickness tends to become thin, and the printing operation must be interrupted occasionally to clean the screen; to lift the screen and spread the coating liquid on the screen Since this printing method involves squeegee operation, there is a disadvantage in that an occupied space required for coating must be secured.

-5
The means for applying by the ink jet method has a limitation in that it is difficult to form a thick coating layer; there is a limitation in continuous operation time because nozzle clogging is likely to occur.

-6-
Therefore, the means for applying by these dispensers, the means for applying by screen printing, and the means for applying by the ink jet method can be adopted as the applying means (M1) in the first step (P1) of the present invention. It is hard to say that it is an optimal means or a suitable means.

-7-
In order to achieve the object of the present invention, as the coating means (M1) for forming the uncured layer (L1), the means described below, that is, the optically transparent resin liquid (R) is applied to the substrate (1). It is particularly preferable that the “coater with a slit nozzle for discharging from a wide slit” suitable for the application region of And it is preferable that this coater can set the discharge amount of 1 time exactly | strictly so that the single wafer processing of a board | substrate (1) can also be coped with.

(Active energy ray irradiation means (M2))
Among the active energy ray irradiation means (M2), as the ultraviolet irradiation apparatus (UV irradiation apparatus) means, there is an irradiation apparatus using a lamp such as a high-pressure mercury lamp, a metal halide lamp (mercury-xenon lamp, etc.), a xenon lamp, or an LED lamp. can give. There are ozone-less types and ozone-type ones, and it is said that there is a difference in surface curability of the coating layer. The coating film output varies. The lamp includes a condensing type and a diffusing type. Regarding the wavelength, it is possible to select a lamp that emits light of various wavelengths, including those having high ultraviolet intensity of 365 nm, those having high ultraviolet intensity of 254 nm, and those containing visible light of 405 nm and 436 nm in addition to these ultraviolet rays. it can.
Various apparatuses can be obtained from each company for the electron beam irradiation apparatus (EB apparatus) in the active energy beam irradiation means (M2).

(Linkage control means (C1))
-1-
The linkage control means (C1) is configured to form the uncured layer (L1) on the substrate (1), the thickened layer (L2), and the thickened state of the thickened layer (L2). This is a means for linking and controlling each process of maintenance. In addition, the process between each process may be a single wafer process for a single substrate (1), or may be a continuous process for a long substrate material or a continuous substrate.

-2-
This linkage control means (C1) sets the substrate (1) at a predetermined position on the line (stage, etc.), and then the first step (P1), the second step (P2), and the third step (P3). In addition to means for moving the substrate (1) to a predetermined location and adjusting the height,
Means for controlling the timing of the start and stop of the application, the adjustment of the application amount, the application amount (M1) with respect to the substrate (1) in the first step (P1);
Means for controlling the irradiation timing of the active energy ray irradiation means (M2) for thickening the uncured layer (L1) on the substrate (1) in the second step (P2);
Means for maintaining the thickening layer (L2) on the substrate (1) in the degree of thickening in the third step (P3) (means for placing it off-line temporarily or for standby);
Etc.

[Production apparatus for optical laminated structure / Part 2]
(Manufacturing apparatus for carrying out the fourth step (P4) to the fifth step (P5))
When performing the fourth step (P4) to the fifth step (P5) after performing the first step (P1) to the third step (P3) of the manufacturing method described above,
After the third step (P3), the laminate having the layer configuration of “thickening layer (L2) / substrate (1)” was bonded to another substrate (2) under vacuum conditions to obtain “substrate (2) / thickening”. A laminating means (M3) for forming a laminate having a layer structure of “layer (L2) / substrate (1)” or “substrate (1) / thickening layer (L2) / substrate (2)”;
Active energy ray irradiation means (M4) for main curing for irradiating active energy rays in the bonded state to make the thickened layer (L2) into a main cured layer (L3);
Coordination control means (C2) for linking and controlling the bonding and main curing processes.
Is required.

(Bonding means (M3))
An example of the bonding means (M3) is schematically shown in the examples described later. As this bonding means (M3), various vacuum bonding apparatuses that have already been put into practical use by the applicant and apparatuses similar to conventionally known vacuum bonding apparatuses can also be used. Note that “vacuum conditions” when pasting together under vacuum conditions means “under reduced pressure conditions”.

(Active energy ray irradiation means (M4))
The active energy ray irradiating means (M4) for main curing for making the thickened layer (L2) described above into the main cured layer (L3) is the same as the active energy ray irradiating means (M2) described above. Is used.

(Linkage control means (C2))
The linkage control means (C2) supplies or moves the substrate (1) and the substrate (2) to a predetermined part in order to perform the fourth step (P4) and the fifth step (P5), Adjust the height, invert, adjust the angle with the help of auxiliary means such as a camera, superimpose both substrates (1) and (2), and adjust the irradiation timing of the energy beam irradiation means (M3) Means for controlling and taking out are included.

Next, the present invention will be further described with reference to examples.

[Example]
(Explanation of drawings)
FIG. 1 is a schematic explanatory view of the manufacturing method and manufacturing apparatus of the present invention as described above.
2A and 2B are explanatory views schematically showing an example of the manufacturing method and the manufacturing apparatus of the present invention, in which FIG. 2A is a plan view and FIG. 2B is a front view.
FIG. 3 is an explanatory view (plan view) schematically showing an example of a vacuum bonding apparatus corresponding to the fourth step (P4) and the fifth step (P5) of the manufacturing method of the present invention.

(First Step (P1) to Third Step (P2))
-1-
2A and 2B, (S) is a stage. The right side of the stage (S) is a set part (S1), the left side of the stage (S) is an application part (S2), and the central part of the stage (S) is an active energy ray irradiation part (S3).
The substrate (1) returns to the position of the first set part (S1) again through the stage (S) through “set part (S1) → application part (S2) → active energy ray irradiation part (S3)”. Is taken out of the system. Subsequent substrates (1) are also put in this cycle one after another. (In FIG. 2, since the set part (S1) and the take-out part are in the same place, the substrate (1) with the thickening layer (L2) for take-out is in the set part (S1)). (It is not shown in the figure. In the above series of cycles, it is easier to see FIG. 1 in which “process (P1) → process (P2) → process (P3)” is drawn in series in this order.)

-2-
One cycle will be described with reference to FIG.
In this embodiment, first, the substrate (1) is manually set on the set unit (S1) on the right side of the stage (S), and then the substrate (1) is applied on the left side of the stage (S) (S2). It was moved by electric.

-3-
Next, in the coating section (S2), the substrate (1) is moved toward the right direction in FIG. 2 at a constant speed, and is directed toward the upper surface of the substrate (1) as an example of the coating means (M1). A predetermined amount of the ultraviolet curable resin liquid (R) is discharged from a coater (with a fixed discharge pump) with a wide slit nozzle and allowed to flow down, whereby an uncured layer (L1) of the resin liquid (R) is formed on the substrate (1). ). (First step (P1))

-4-
Subsequently, while the substrate (1) on which the uncured layer (L1) is formed passes through the active energy ray irradiating part (S3) at the center of the stage (S) at the same speed as described above, the active energy ray irradiating means A predetermined amount of ultraviolet irradiation was performed from (M2) to thicken the uncured layer (L1) formed on the substrate (1) to form a thickened layer (L2). (Second step (P2))

-5
Subsequently, the substrate (1) on which the thickening layer (L2) is formed is electrically moved at the same speed as described above, and moved to the original set position (S1) on the right side of the stage (S). Then, the substrate (1) on which the thickening layer (L2) was formed was manually moved to a standby part (not shown).

-6-
In the standby section, the laminated structure “thickening layer (L2) / substrate (1)” was stored for an arbitrary time (for example, several hours to several days), but the thickening layer (L2) remained in the same thickened state. Kept in. In this standby state, the thickening layer (L2) is exposed to air (that is, oxygen), but no phenomenon has been observed in which the curing proceeds to the main curing. (Third step (P3))

(4th process (P4) to 5th process (P5))
-1-
Laminated structure composed of “thickening layer (L2) / substrate (1)” in the third step (P3) placed in the standby state to perform the fourth step (P4) and the fifth step (P5). The body was supplied to the vacuum bonding apparatus shown in FIG.

-2-
The lower left part of FIG. 3 is a set part (Z1) of one substrate or the like (substrate or substrate laminate) to be bonded, and the lower right part of FIG. 3 is the other substrate or the like (substrate or substrate) to be bonded. It is a set part (Z2) of a board | substrate laminated body.
The upper left part of FIG. 3 is a delivery part (Z3) for delivering a substrate or the like from the lower left part to the upper right part.
The upper right portion in FIG. 3 is a bonding portion (Z4) for bonding a substrate or the like from the upper left portion and a substrate or the like from the lower right portion under vacuum.

-3-
First, the laminated structure of “thickening layer (L2) / substrate (1)” after the third step (P3) after the second step (P2) was set in the lower right set portion (Z2). .
On the other hand, the substrate (2) was set in the lower left set part (Z1).
Next, the substrate (2) was moved to the upper left set part (Z3).

-4-
Next, the substrate (2) in the upper left set part (Z3) is moved to the upper right bonding part (Z4), and the “thickening layer (L2) / substrate (1) in the lower right set part (Z2) is moved. ) ”Was placed by moving it to the upper right bonding portion (Z4), and then a fourth step (P4) was performed in which bonding was performed under vacuum at the bonding portion (Z4).

-5
As a result, bonding was performed under vacuum conditions, and a bonded structure having a layer configuration of “substrate (2) / thickening layer (L2) / substrate (1)” was obtained. The 5th process (P5) which makes the previous thickening layer (L3) the last thickening layer (L3) by the ultraviolet irradiation from the abbreviated active energy ray irradiation means (M3) was carried out.

-6-
After releasing the vacuum, the bonded structure was moved to the lower right set part (Z2) in FIG. 3 and taken out of the vacuum bonding apparatus. As a result, a final laminated structure composed of “substrate (1) / main cured layer (L3) / substrate (2)” was produced.

(Set conditions and results)
-1-
In this example, the conditions were set as follows.
-Substrate (1): Glass substrate, size is 190 mm x 240 mm
-Substrate (2): A substrate with a 15 mm width border (2E) which is a white decorative part, the size is 190 mm x 240 mm
・ Optical transparent resin liquid (R): radical polymerization type acrylic UV curable resin liquid ・ Viscosity degree of the above optical transparent resin liquid (R) η: 3000 mPa / 25 ° C. as measured according to ASTM D1084
-Application area of uncured layer (L1): 160 mm x 210 mm
・ Uncured layer (L1) thickness: 150 μm and 200 μm in two levels ・ Uncured layer (L1) viscosity η: almost the same as the viscosity of the resin liquid (R) ・ Uncured layer (L2) cure rate: 0 %
-Curing rate of thickening layer (L2): 3 levels of 30%, 50%, 70%-Curing rate of main cured layer (L3): almost 100%
・ Thickness of edge (2E) of substrate (2): two levels of 80 μm and 50 μm

-2-
Each of the 12 permutations of the above 2 levels × 3 levels × 2 levels in total is visually observed from the side of the substrate (2). In any of these 12 levels, a strip shape along the step with the border (2E). No bubble (b) was observed.
By the way, when bonding is performed using the substrate (1) and the substrate (2E) with the edging (2E) according to the conventional OCA adhering method, a band-like shape along the step with the edging (2E) is used. It was inevitable that bubbles (b) were seen.

The optical laminated structure produced by the method and apparatus of the present invention is extremely useful as an electronic device including a display device and an input device.

It is typical explanatory drawing of the manufacturing method and manufacturing apparatus of this invention. It is explanatory drawing which showed typically an example of the manufacturing method and manufacturing apparatus of this invention, (A) is a top view, (B) is a front view. It is explanatory drawing (plan view) which showed typically an example of the vacuum bonding apparatus corresponded to the 4th process (P4) and 5th process (P5) of the manufacturing method of this invention. It is a schematic diagram for demonstrating the problem of the conventional OCR coating method. It is a schematic diagram for demonstrating the problem of the conventional OCA sticking method.

(1) ... substrate,
(2) ... substrate,
(2E) ... border,
(L1) ... uncured layer,
(L2) ... thickening layer,
(L3) ... this hardened layer,
(P1) ... 1st process,
(P2) ... 2nd process,
(P3) ... 3rd process,
(P4) ... 4th process,
(P5) ... 5th process,
(M1) Application means,
(M2) ... active energy ray irradiation means,
(M3) ... active energy ray irradiation means,
(S) ... Stage,
(S1) ... set part,
(S2) ... application part,
(S3) ... active energy ray irradiation part,
(Z1) ... set part,
(Z2) ... set part,
(Z3) ... standby unit,
(Z4) ... Lamination part,
(OCR): Optically transparent resin,
(OCA) ... optical transparent adhesive,
(B) ... strip-shaped bubbles

Claims (5)

1. By applying a radical polymerization type active energy ray-curable optically transparent resin liquid (R) on the substrate (1), the resin liquid (R) has a single-layered fluid uncured state on the substrate (1). A first step (P1) for obtaining a laminate having a layer configuration of “uncured layer (L1) / substrate (1)” in which the layer (L1) is formed;
   By irradiating an active energy ray to the uncured layer (L1) of the laminate obtained in the first step (P1) to advance the curing, the uncured layer (L1) has reduced fluidity. A second step (P2) for obtaining a laminate having a layer configuration of “thickening layer (L2) / substrate (1)” changed to a thickening layer (L2); and
   Third step (P3) for maintaining the thickened layer (L2) of the layered structure of “thickened layer (L2) / substrate (1)” after the second step (P2) in its thickened state.
   The manufacturing method of the laminated structure for optics characterized by these.
2. After the third step (P3),
   The laminated body having the layer configuration of “thickening layer (L2) / substrate (1)” is bonded to another substrate (2) under vacuum conditions, and “substrate (2) / thickening layer (L2) / substrate ( 1) "or the fourth step (P4) for forming a laminate having a layer structure of" substrate (1) / thickening layer (L2) / substrate (2) ";
   5th process (P5) which irradiates an active energy ray in the bonded state, and makes the said thickening layer (L2) into this hardened layer (L3)
   The manufacturing method according to claim 1, wherein:
3. By applying a radical polymerization type active energy ray-curable optically transparent resin liquid (R) on the substrate (1), the resin liquid (R) has a single-layered fluid uncured state on the substrate (1). Application means (M1) for obtaining a laminate having a layer structure of “uncured layer (L1) / substrate (1)” in which the layer (L1) is formed,
   By irradiating active energy rays to the uncured layer (L1) of the laminate having the layer structure of “uncured layer (L1) / substrate (1)”, the uncured layer (L1) is cured. ) Is a thickened active energy ray irradiating means (M2) for forming a layered product of “thickened layer (L2) / substrate (1)” in which the thickened layer (L2) is reduced in fluidity. )When,
   Linking and controlling each step of forming the uncured layer (L1) on the substrate (1), forming the thickened layer (L2), and maintaining the thickened state of the thickened layer (L2) Linkage control means (C1)
   An optical laminated structure manufacturing apparatus comprising:
4. The coating means (M1) for forming the uncured layer (L1) is a coater with a slit nozzle for discharging the optical transparent resin liquid (R) from a wide slit;
   The manufacturing apparatus according to claim 3.
5. After the formation of the uncured layer (L1), the formation of the thickening layer (L2), and the maintenance of the thickening state of the thickening layer (L2), the “thickening layer (L2) / substrate (1) ) ”Is laminated with another substrate (2) under vacuum conditions, and“ substrate (2) / thickening layer (L2) / substrate (1) ”or“ substrate (1) / thickening ” Bonding means (C2) for forming a layered product of a layer configuration of “layer (L2) / substrate (2)”;
   Active energy ray irradiation means (M3) for main curing for irradiating active energy rays in the bonded state to make the thickened layer (L2) into a main cured layer (L3);
   Coordination control means (C3) for linking and controlling the bonding and main curing steps.
   The manufacturing apparatus of Claim 3 comprised.
   
   

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